Process for forming a paper, burlap or cloth flower pot cover

ABSTRACT

A method for making a flower pot cover by treating a sheet of material which is non-shape sustaining with a shape-sustaining wax capable of imparting dead fold characteristics and forming the treated sheet of material into a predetermined shape of a flower pot cover.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Ser. No. 407,871entitled A PROCESS FOR FORMING A PAPER, BURLAP OR CLOTH FLOWER POT COVERfiled Sep. 15, 1989 which is a continuation-in-part of U.S. Ser. No.357,978 entitled A PROCESS FOR FORMING A PAPER, BURLAP OR CLOTH FLOWERPOT COVER filed May 26, 1989 which is a continuation-in-part of U.S.Ser. No. 314,951 entitled A PROCESS FOR FORMING A BURLAP OR CLOTH FLOWERPOT COVER, filed Feb. 24, 1989. These applications are herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a process for forming a flower potcover by treating a sheet of natural or synthetic burlap or combinationsthereof, a natural or synthetic fiber or combinations thereof, or paperby placing a sheet of this material over a sheet of material capable ofbeing formed into a predetermined shape by forming a plurality ofoverlapping folds in said material, and then forming the two sheetssimultaneously into the predetermined shape of a flower pot cover; or byapplying a shape-sustaining agent to at least one sheet of the material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a flower pot cover formed by the processof the present invention.

FIG. 2 is a sectional view showing two sheets of material used to formthe flower pot cover shown in FIG. 1 disposed generally between a maledie and a female die.

FIG. 3 is a partial sectional view of a portion of the flower pot covershown in FIG. 1 and illustrating the overlapping folds used to form theflower pot cover shown in FIG. 1.

FIG. 4 is a sectional view showing one sheet of material treated with ashape-sustaining agent used to form a flower pot cover in the shapeshown in FIG. 1.

FIG. 5 is a sectional view showing two sheets of material used to form aflower pot cover disposed generally between a male die and a female die.

FIG. 6 is a sectional view showing three sheets of material used to forma flower pot cover disposed generally between a male die and a femaledie.

FIG. 7 is a sectional view of a flower pot cover used as a floralcontainer.

FIG. 8 is a sectional view of a flower pot cover used to receive aflower pot.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Shown in FIG. 1 and designated therein by the general reference numeral10 is a flower pot cover constructed in accordance with the presentinvention. "Flower Pot Cover" means a floral container or a cover whichreceives a flower pot. "Floral Container" is a container which will beused for floral arrangements such as made from cut flowers, driedmaterials, silk flowers and other artificial flowers, and otherdecorations. One such floral container is shown in FIG. 7 wherestyrofoam 42 or another such substance capable of receiving stems 44,for example, is disposed inside the flower pot cover 10a. FIG. 8 showsthe flower pot cover 10b having a flower pot contained therein. Theflower pot 46 contains dirt 48 and flowers 50. The flower pot cover hasan upper end 12 and a lower end 14. An object opening 16 is formedthrough the upper end 12 of the flower pot cover 10 and the objectopening 16 extends a distance through the flower pot cover 10. Theobject opening 16 is sized and shaped to receive a flower pot. A skirt18 is formed on the upper end 12 of the flower pot cover 10 and theskirt 18 extends a distance outwardly from the upper end 12 of theflower pot cover 10. The flower pot cover 10 is formed in thepredetermined shape of the flower pot cover 10 by forming a plurality ofoverlapping folds, only some of the overlapping folds being shown inFIG. 1 diagrammatically and designated therein by the general referencenumeral 20. A flower pot cover constructed by forming overlapping foldsin a sheet of material using a male and a female die is described indetail in U.S. Pat. No. 4,773,182, entitled "ARTICLE FORMING SYSTEM",issued Sep. 27, 1988, specifically herein incorporated by reference.

The flower pot cover 10 may be constructed from at least one sheet ofmaterial selected from a group of materials comprising a natural orsynthetic burlap or combinations thereof, a natural or synthetic fiberor combinations thereof or any form of paper including, but not limitedto waxed paper and paper towels. "Fiber" as used herein may be any typeof fibrous material such as cloth, e.g., wool, cotton, polyester, rayonand blends thereof including denim.

These particular materials are normally non-shape sustaining in that ifthese materials were formed in the shape of a flower pot cover, thematerials would not function to retain that shape. Therefore, thesematerials are treated in order to retain a shape as described hereinand/or combined with at least a second sheet of material capable ofretaining a shape as shown in FIG. 1 and described herein.

In one embodiment, the flower pot cover 10 is formed from a first sheetof material 22 and a second sheet of material 24 with the first and thesecond sheets of material 22 and 24 being shown in FIG. 2. The firstsheet of material 22 has an upper surface 26, a lower surface 28 and anouter peripheral surface 30. The second sheet of material 24 has anupper surface 32, a lower surface 34 and an outer peripheral surface 36.The first sheet of material is placed generally over the second sheet ofmaterial so that the lower surface 28 of the first sheet of material isdisposed generally adjacent the upper surface 32 of the second sheet ofmaterial 24. The first and the second sheets of material 22 and 24 thenare disposed generally over a female die 38 and a male die 40 then isbrought into mating engagement with the female die 38 with the first andthe second sheets of material 22 and 24 being disposed generally betweenthe male and the female dies 40 and 38 for forming the first and thesecond sheets of material 22 and 24 into the predetermined shape of theflower pot cover 10. During the forming process as the male and thefemale dies 40 and 38 are brought into mating engagement, theoverlapping folds 20 are formed in the sheets of material 22 and 24.

In FIG. 2, the flower pot cover formed as previously described has thesecond sheet 24 of material on the outside of the flower pot cover. InFIG. 5, the flower pot cover formed as previously described has thefirst sheet 22a of material on the outside of the flower pot cover. InFIG. 6, the flower pot cover formed as previously described has thefirst sheet 22b of material between two second sheets 24b, 24c ofmaterial. In FIG. 4, a flower pot cover 10 comprising a first sheet ofmaterial 22 treated with a shape-sustaining agent, as describedhereafter, is formed from a female die 38 and a male die 40 in the samemanner as previously described.

The first sheet of material 22 is formed from a material selected from agroup of materials comprising a natural or synthetic burlap orcombinations thereof, a natural or synthetic fiber or combinationsthereof, or paper. The second sheet of material 24 is formed of amaterial which is capable of being formed into a predetermined shape byforming a plurality of overlapping folds in this material wherein theoverlapping folds cooperate to provide the structural integrity forcooperating to hold this particular material in the formed,predetermined shape. The second sheet of material 24 is formed of amaterial preferably selected from a group of materials comprising aman-made processed organic polymer film, a cellophane, paper, foil orcombinations thereof.

The term "processed organic polymer film" as used herein means aman-made resin such as polypropylene as opposed to naturally occurringresins such as cellophane. A processed organic polymer film isrelatively strong and is not as readily subject to tearing(substantially non-tearable) as paper or foil for example. Such filmsare synthetic polymers formed or synthesized from monomers. A processedorganic polymer film is virtually waterproof which is desirable whenforming a flower pot cover and which is not true of an untreated paper,for example, unless the paper is treated with a water resistant coatingor impregnated with a water resistant material or laminated with awaterproofing material. It also should be noted that some paper such aslong fiber papers are substantially resistant to tearing (substantiallynon-tearable). The processed organic polymer film also is not subject todeterioration and sunlight as may be a cellophane for example.

In the present application, the second sheet of material 24 preferablyis a relatively thin sheet of material having a thickness in a range offrom less than about 1.0 mils to about 2.5 mils. The upper limit on thethickness may vary depending on the type of material selected. The upperlimit on the thickness is set such that the material retains flexibilityand foldability. As a practical matter, the upper limit is about 20mils.

A decorative pattern such as a solid color and/or an embossed pattern(not shown) and/or other decorative surface ornamentation is applied tothe upper or lower surfaces 32 or 34 or both in one preferredembodiment.

The second sheet of material 24 may be thermal setting in the sensethat, when the male and the female dies 38 and 40 are brought intomating engagement and heat is applied to either the male or the female40 or 38 or both, the overlapping folds 20 are substantially permanentlyformed in the second sheet of material 24. Further, when heat isapplied, the overlapping folds formed in the second sheet of material 24are adhered or connected to adjacent portions of the second sheet ofmaterial 24 for cooperating to maintain the structural integrity of thepredetermined, formed shape. In these instances, heat is applied toeither the male die 40 or the female die 38 or both.

In another embodiment, an adhesive also may be applied to the uppersurface 32 or the lower surface 34 or both of the second sheet ofmaterial 24 so that adjacent portions of the second sheet of material 24are adhesively connected when the overlapping folds 20 are formed in thesecond sheet of material.

The overlapping folds formed in the second sheet of material 24 areinterleafed in the overlapping folds formed in the first sheet ofmaterial 22 during the forming process. This interleafing of theoverlapping folds 20 formed in the first and the second sheets ofmaterial 22 and 24 cooperate to connect the second sheet of material 24to the first sheet of material 22. Further, this interleafing of theoverlapping folds 2 and the first and the second sheets of material 22and 24 cooperate so that the overlapping folds in the second sheet ofmaterial 24 cooperate with the overlapping folds with the first sheet ofmaterial 22 so that the second sheet of material 24 cooperates to holdthe first sheet of material 22 in the predetermined shape of the flowerpot cover 10 after the forming process.

In one preferred form, the second sheet of material 24 is adhesivelyconnected or laminated to the first sheet of material 22 prior toplacing the sheets of material 22 and 24 between the male and femaledies 40 and 38 forming the flower pot cover.

In one preferred form, the burlap first sheet of material is moistenedand then placed on the second sheet of material. The first and secondsheets of material 22 and 24 then are formed into the pot cover.

In one other form, a second sheet of material may be placed on bothsides of the first sheet of material which may enhance the structuralintegrity in some applications.

In one preferred form, overlapping folds such as the overlapping folds20 are not formed in the skirt 18.

In one other form, an adhesive is applied to the upper surface 26 or thelower surface 28 or both of the first sheet of material 22. In thisform, the first sheet of material 22 without the second sheet ofmaterial 24 is placed between the male and the female die 40 and 38 andthe predetermined shape of the flower pot cover 10 is formed by bringingthe male and the female dies 40 and 38 into mating engagement with thefirst sheet of material 22 disposed therebetween. The adhesive on theupper or lower surfaces 26 or 28 or both of the first sheet of material22 cooperates to adhesively connect adjacent portions of the secondsheet of material 22 when the overlapping folds 20 are formed in thefirst sheet of material 22. In this instance, the adhesively adheredoverlapping folds 20 in the first sheet of material 22 cooperate tomaintain the structural integrity of the predetermined shape of theflower pot cover in the formed first sheet of material 22. In thisparticular example, the first sheet of material normally is notwaterproof and, in some applications, it is desirable to treat the firstsheet of material 22 with a waterproofing substance to impart awaterproofing characteristic to the first sheet of material 22. Thewaterproofing characteristic also can be accomplished by laminating awaterproof paper or film to the first sheet of material 22 prior toforming the first sheet of material 22 in the predetermined shape of theflower pot cover 10.

Adhesive may also be applied to glue down the folds 20 after the flowerpot cover 10 has been formed if any folds require further restraint.Usually this will only be needed for larger folds 20 formed in theflower pot cover 10 on the outer surface of the flower pot cover 10.

Since the first sheet of material 22 normally is non-shape sustaining,the first sheet of material 22 also can be formed in the predeterminedshape of the flower pot cover 10 by treating the first sheet of material22 with a shape-sustaining agent capable of imparting a dead foldcharacteristic to the first sheet of material 22. The term "dead fold"as used herein means that the material when folded will substantiallyfunction to retain the folded shape. The shape-sustaining agent fortreating the first sheet of material may be a sugar, glue, starch, orwax for example. Referring to FIG. 4, the first sheet of material 22treated with the shape-sustaining agent is placed between a female die38 and a male die 40 as previously described and formed into apredetermined flower pot cover. The flower pot cover can be formed inthe predetermined shape of the flower pot cover 10 by forming theoverlapping folds 20 and the imparted dead fold characteristic willcooperate with the first sheet of material 22 so that the first sheet ofmaterial 22 retains the predetermined shape of the flower pot coverwithout having to use the second sheet of material.

The shape-sustaining treatment of the flower pot cover 10 may comprisethe addition of any shape-sustaining agent to the sheet of material 22which provides the necessary dead fold characteristics thereto.Preferably the shape-sustaining agent is selected from the groupconsisting of sugar, glue, starch or wax. The shape-sustaining agent isin a form which substantially uniformly covers the sheet of material 22or can be applied to the dies 38 and 40 to adhere to the sheet ofmaterial 22, e.g., powder or liquid. The shape-sustaining agent isapplied to the sheet of material or the dies 38 and 40 prior to placingthe sheet of material between the dies 38 and 40.

Starch as used herein means any stiffening or sizing agent such as acarbohydrate polymer which may impart dead fold characteristics to thematerial utilized in accordance with the present invention. The starchmay be in powdered or liquid form. If in a liquid form, the liquidstarch may be sprayed on the material, or the sheet of material dippedin the liquid. If the starch dries on the material and if this is notacceptable to the process, the material may be moistened prior toexposure to the dies.

In a preferred embodiment, a spray starch such as Niagara Spray Starchby Best Foods, CPC International, Inc., Englewood Cliffs, New Jersey, issprayed onto a sheet of burlap in a quantity sufficient to impart deadfold characteristics to the burlap. The treated burlap is placed betweenthe male and female dies 40 and 38 as previously described and a flowerpot cover 10 is formed as described herein.

In another embodiment, sucrose (one type of sugar) and a diluent such aswater is mixed until the sugar dissolves. A sufficient amount of sugaris added to the diluent which will impart a dead fold characteristic tothe material utilized in accordance with the present invention. Thiswill, in part, depend upon the type of material utilized and thethickness of the material. The sugar mixture is then applied to theupper surface and/or the lower surface of a paper towel such as Premieretowels made by Scott Paper Co., Philadelphia, PA. The sugar mixture maybe sprayed on the sheet of material or the sheet of material dipped inthe sugar mixture before the flower pot 10 is formed. If the sugarmixture dries on the material and if this is unacceptable to theprocess, the material may be moistened before exposure to the dies.

Wax as used herein means any natural or synthetic wax which possessesappropriate shape-sustaining or sealing properties. Such a natural waxmay be animal wax, such as but not limited to beeswax, lanolin orshellac wax; vegetable wax, such as but not restricted to bayberry,carnauba or sugar cane; or mineral, such as but not limited to fossil orearth waxes, petroleum waxes and various paraffin waxes. Synthetic waxesmay be, but are not restricted to, ethylenic polymers, chlorinatednapthalenes and various waxy hydrocarbons.

With respect to its function, wax may be used to impart dead foldcharacteristics to the material, to provide a sealing agent for theoverlapping folds of the material, or a combination of providing deadfold properties and a sealant for the folds.

Various methods may be used to apply the wax to the flower pot covermaterial. If necessary, the wax may be heated sufficiently to form aliquid and the material may be dipped in the liquid wax. In anotherembodiment, a wax with appropriate characteristics may be sprayed ontothe material. Any other suitable method may be used to apply the wax tothe flower pot cover material.

Changes may be made in the construction and the operation of the variouscomponents and assemblies described herein and changes may be made inthe step or the sequence of steps of the methods described hereinwithout departing from the spirit and the scope of the invention asdefined in the following claims.

What is claimed is:
 1. A method for making a flower pot cover having anouter peripheral surface which comprises the steps of:treating a firstsheet of material selected from a group of materials comprising anon-shape sustaining natural or synthetic or burlap or combinationsthereof, a non-shape sustaining natural or synthetic fiber orcombinations thereof, or paper with a shape-sustaining wax capable ofimparting a dead fold characteristic to the first sheet of materialwhereby the first sheet of material .is capable of being formed into apredetermined shape of the flower pot cover by forming a plurality ofoverlapping folds in the first sheet of material wherein the overlappingfolds cooperate to provide the structural integrity for cooperating tohold the first sheet of material in the predetermined shape of theflower pot cover; and forming the first sheet of material into apredetermined shape of the flower pot cover by forming overlapping foldsin the first sheet of material, the overlapping folds in the first sheetof material cooperating to maintain the first sheet of material in thepredetermined shape of the flower pot cover.
 2. The method of claim 1further comprising placing the first sheet of material treated with theshape-sustaining agent over the second sheet of material before thematerial is formed into the shape of a flower pot cover and forming aflower pot cover from the first sheet of treated material and the secondsheet of material.
 3. The method of claim 2 wherein the second sheet ofmaterial is waterproof.
 4. The method of claim 2 further comprisingconnecting the first sheet of material to the second sheet of materialprior to forming the first and the second sheets of material into thepredetermined shape of the flowerpot cover.
 5. The method of claim 2wherein the second sheet is further defined as being non-shapesustaining.